That would be a sweet tour!
It was!
I just got an email from Randy's with their new QC equipment/rooms. So apparently it's not top secret enough that I can't share
http://www.ringpinion.com/Quality.aspx
The two pictures on this page are just of the one room, roughly 8x16. The one big machine in the first picture is a big marble slab with a gantry type deal. They then bolt the part to the table, and this gantry probes the entire part and compares the part to the drawing, down to .0002". Figure 1.4 shows the points they are verifying. Any guess to what part it is?
Both rooms are temp/humidi controlled. Before a part is tested, the part is brought into the room to sit for 24? (might have been 36?) hours and normalize.
Then there is the article
http://www.ringpinion.com/Content/Quality_Control_Tech_Report.pdf
Figure 2.3 is a tool that measures how 'rough' the face of the gear is. Randy's designs their own gears, rather than using OEM or other manufactures designs. This enables them to control how their gears are made - they now have an industry first, a quiet gear set for the Chrysler 9.25! Not even Chrysler has a quiet gear set
If the surface is too rough, then the gear is reboxed as a USA Standard gear and will not make it into a Yukon box. This is in their other room, which is about 20x25?
Figure 3.3 is where the Spectrometer checks the material. It comes back with how much of each ingredient is in the material. The computer then has a database and by this, the computer then spits out what material it actually is. You can see all of the numbers blurred out to the right and to the left each 'ingredient'
The door behind figure 7.1 is their larger QC lab.
Figure 7.5 is one of their D44 shafts in purple and a competitors in pink. The machine actually spits out this print out, too. Randy focuses on strength, rather than deflection. You can see this very clearly in the chart. The competitors shaft almost completely twisted before it broke, the whole time the tire probably wasn't even turning. Some deflection is necessary to absorb shock loads. But Randy figures it's more important to maintain the shaft when you are bound up, so you can pull yourself out of it before busting the shaft.
The one shaft we tested while I was there busted at the ears and Randy was very shocked to see it break there. That shaft was then analyzed to figure out why it broke there and not down at the splines like normally.
Notice their standard 4340 shaft will go beyond 6,000 ftlbs of torque before failure
Spicer 760 joint is rated at 5400 ftlbs.
Recognize the part in Figure 9.1? That's a Grizzly driver being tested. Not sure what I can say here and not share a trade secret...
Anyway, very cool indeed!!!